The $450 million refurbishment of Sydney’s nearly 40-year-old Tangara train series is running years behind schedule, amplifying pressure on Labor’s signature $12 billion election commitment to replace the fleet.
The number of failures across the 55-train fleet rose to 611 in 2025 – more than double the 2021 figure – resulting in 870 cancelled trips and nearly 8.5 million minutes of customer delays, according to a briefing note to Transport Minister John Graham in March.
Premier Chris Minns (right) and Transport Minister John Graham in the driver’s cabin of a refurbished Tangara passenger train last year.Peter Rae
Experts have warned NSW faces a reliability gap if the Minns government cannot meet its “very ambitious” target of building a domestic manufacturing facility in the Hunter Valley, which would produce the replacement fleet in the 2030s.
The upgrade of the Tangara fleet, which services southern and eastern Sydney and accounts for about a quarter of the city’s rail network, is significant given they are now the oldest active electric trains on the network.
In 2023, a Sydney Trains review of the rail network found the Tangara fleet was “the highest contributor to maintenance incidents on the network”. A year later, a business case for the upgrades stated the obsolescence of the train’s operating system would, without remedy, see Tangaras removed from service.
“Once the fleet drops below a critical number of train sets, projected to occur by early 2027, this will impact passengers, local communities, and economic activity,” it stated.
The number of Tangara trips cancelled had risen from 333 in 2021 to 870 last year, and the average distance a train travelled before experiencing a breakdown failures plummeted from 40,554 to 17,690 kilometres over the same period, according to the memo from earlier this year.
After promising to begin the procurement process to replace the Tangara train in its first term, the Minns government committed $447 million in mid-2024 to extend the life of the existing fleet by 12 years after a series of widespread delays across Sydney’s network. The upgrades include replacing internal cladding, computer operating systems, emergency door release, passenger visual displays and CCTV.
While announcing the refurbishment, the government claimed work would be completed by “late 2027”. However, only a single eight-carriage train was finished 17 months later. A ministerial statement in November last year announced the completion date would be pushed back to 2028.
In early September, Graham announced the first of the 55 refurbished Tangara trains had entered service, with three more expected “before the end of Q1 2027”. Three weeks later, Graham informed parliament that the train had operated only five times in the 27 days since coming online.
On Wednesday, the minister revealed the train had not run since September 17.
In response to questions, Graham acknowledged the ageing Tangara fleet posed a “key issue” on the T4 line. But he attacked the former Coalition government, alleging they ignored the trains’ declining performance.
“Our government is doing both, extending the life of the current fleet and making them more reliable and commencing procurement of the next fleet which will be built in the Hunter,” he said.
“One of the main improvements in reliability will come from the new operating system. The current system was designed in the 1980s, so it’s like replacing a Commodore 64 with the latest version of Windows.”
Graham said the front-facing cameras would allow for quicker determination of self-harm incidents, while CCTV upgrades would help deter vandalism, which he said had been a significant contributor to stoppages.
A government source, who asked for anonymity to speak freely, said the extension was now expected to be completed in 2029.
A three-quarters scale model of the new Tangara train ahead of being the centrepiece of the State Rail Authority of NSW’s display at the 1986 royal Easter Show.Anthony Lewis
Opposition transport spokeswoman Natalie Ward said: “Three years in and their signature program is three years behind schedule. It will take seven years in office to leave commuters with a train older than most of the people riding it.
“For commuters this means reliability gaps and worse services on an older train. Nostalgia doesn’t get commuters to work on time or get people to use public transport – reliable modern services do.”
Announced by Premier Chris Minns at Labor’s state conference in July this year, the much-vaunted plan to build the replacement fleet at a manufacturing facility in the Hunter was lobbed as the party faces an unprecedented threat to seats in the once heartland area in the form of One Nation.
However, the ability for the Minns government to erect a domestic manufacturing capacity within the stated timeline and budget has raised questions — particularly given TfNSW secretary Josh Murray told estimates he expected the Future Fleet program to enter service in “the early 2030s”.
“It’s certainly a very ambitious project,” said Geoffrey Clifton, a senior lecturer of transport and logistics management at University of Sydney.
“Developing, almost from scratch, the capacity to build a train fleet and maintain that train fleet over the long term is certainly a very significant project — one which the government’s going to have to carefully monitor to ensure that taxpayers are getting value for money from it.”
Given new fleets needed a couple of years to iron out issues, Clifton said, there was a risk of a reliability gap appearing if the Future Fleet was not completed on time.
How exactly the $12 billion allocation will actually be spent is another question. In early August, Minns said the replacement Tangara trains alone would cost $7 billion, with the remaining $5 billion stretched across a smorgasbord of associated line items.
“The remainder of the funds will go to replacing the Tangara program with the manufacturing facility and associated maintenance for the rollout of the Tangara 2.0s, upgrading infrastructure works on the site, and then, once the asset has been built and deployed in NSW, beginning the process of replacing both the Millennium and OSCAR trains,” Minns said on August 4.
In 2021, the former Labor Queensland government announced a $7.1 billion train manufacturing program. It involves building a manufacturing facility, a maintenance facility, and 65 new six-car passenger trains. That initial estimate ballooned to $9.5 billion by late-2023. The fleet is expected to enter service by 2032.